SEDEMAC GC1100 Manuel utilisateur

MANUAL FOR

GC1100:

GENSET

CONTROLLER

Product Manual Version #0.00

ABSTRACT

This manual is intended as

an information guide for

operating SEDEMAC's GC1100

genset controller.

Doc #SED-MAN-GC1100-002

Date: 20-Apr-2018

by any means (including photocopying or storing in any medium by electronic means or other)

without the prior written permission of the copyright holder. Any reference to trademarked

product names used within this publication is owned by their respective companies.

SEDEMAC Mechatronics Pvt. Ltd. reserves the right to change the contents of this document

without prior notice. For permission requests and applications to reproduce any part of this

publication should be addressed to SEDEMAC Mechatronics Pvt. Ltd at below mentioned

contact details.

SEDEMAC Mechatronics Pvt. Ltd.

C9-10, C Block, MIDC Bhosari

Pune 411026, INDIA

Web Support:

Email: support@sedemac.com

Website: www.sedemac.com

Telephonic Support:

+91-20-67313500

+91-8551041888

+91-8551043888

+91-8551933888

+91-8551039888

GC1100 SEDEMAC

Page | i

Safety Instructions

General Instructions

✓This document includes important instructions that should be followed during installation and

maintenance of the generator Set controller.

✓For safety reasons, the manufacturer recommends that this equipment be installed and serviced by an

authorized service personnel. Follow all applicable state and local electrical codes.

✓Efficient and safe operation of the controller can be acquired only if the equipment is correctly

operated, configured and maintained. Many accidents arise due to ignorance or illiteracy towards the

elemental rules of safety and precautions.

The following safety notations found throughout this document indicate potentially hazardous conditions

to the operator, service personnel or the equipment.

•Highlights an essential element of a procedure to ensure correctness

•Indicates a procedure or practice, which could result in damage or

destruction of equipment, if not strictly observed

•Indicates a procedure or practice, which could result in injuring

personnel or loss of life, if not followed correctly

Electrical Safety

✓Electric shock can cause severe personal injury or death.

✓Ensure the generator set must be grounded before performing any installation or service.

✓Generators produce high electrical voltages, direct contact with it can cause fatal electrical shock.

Prevent contact with terminals, bare wires, connections, etc., while the generator and related equip-

ment are running. Do not tamper with interlocks.

✓To handle the maximum electrical current, sizes of wire gauge used for electrical connections and wir-

ings must be appropriate to which they will be subjected to.

In Operation Safety

✓Before installing genset controller, ensure that all power voltage supplies are positively turned off at

their source. Disconnect the generator’s battery cables and remove panel fuse to prevent accidental

start up. Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first.

Reconnect the negative cable last. Failure to do so will result in hazardous and possibly fatal electrical

shock.

✓Remove electric power supply before removing controller or touching other electrical parts.

✓Use extreme caution when working on electrical components. High voltage can cause injury or death.

✓Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when

working near generator set or other electrical equipment.

✓Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling

electrical equipment.

✓Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or

feet are wet. It may result in severe electrical shock.

GC1100 SEDEMAC

Page | ii

✓Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock

or burning.

✓In case of an accident caused by electric shock, immediately shut down the electrical power source. If

this is not possible, try to release the victim from the live conductor. Avoid direct contact with the

victim. Use a nonconducting object, like, a rope or wooden stick, to release the victim from the live

conductor. If the victim is unconscious, apply first aid and get immediate medical help.

GC1100 SEDEMAC

Page | iii

List of Abbreviation

This list contains the list of acronyms used in this document and it can be used to refer their

respective description. This list does not contain units of measure.

Acronym

Description

Alternating Current

ACK

Acknowledge

ALT

Alternator

AMF

Auto Mains Failure

AUX

Auxiliary

BTS

Base Transceiver Station

CHG

Charging

CKT

Circuit

Current Transformer

Direct Current

Diesel Generator

DIG IN

Digital Input

ENG TEMP

Engine Temperature

ETS

Engine Temperature Sensor

FLS

Fuel Level Sensor

GCU

Genset Control Unit

Genset

Generator Set

GND

Ground

HMI

Human Machine Interface

HSD

High Side Driver

HWT

High Water Temperature

LCD

Liquid Crystal Display

LED

Light Emitting Diode

LLOP

Low Lube Oil Pressure

LOP

Lube Oil Pressure

LVL

Level

MCP

Manual Control Panel

MPU

Magnetic Pickup Unit

Over Voltage

PID

Proportional Integral Derivative

PWM

Pulse Width Modulation

RMS

Root Mean Square

RPM

Revolutions Per Minute

R-Y-B

Red-Yellow-Blue

SCP

Sensor Common Point

SMD

State Machine Diagram

TEMP

Temperature

USB

Universal Serial Bus

Under Voltage

 
GC1100 SEDEMAC 
 
Page | iv 
 
Table of Contents 
1Introduction..........................................................................................................................1
 Key Highlights of the Product..........................................................................................1
 Product Features.............................................................................................................1
 Specifications ......................................................................................................................3
 Terminals.........................................................................................................................3
 Power Supply Specifications...........................................................................................4
 Generator Voltages and Frequency Measurements........................................................4
 Load Current Measurements...........................................................................................5
 Mains Voltage and Frequency Measurements ................................................................5
 Digital Inputs ...................................................................................................................6
 Analog Resistive Sensor Inputs ......................................................................................6
 Analog Current Input .......................................................................................................7
 Magnetic Pick Up Input ...................................................................................................7
 Digital Outputs .............................................................................................................7
 D+ CHG ALT ................................................................................................................8
 Sensor Common Point.................................................................................................8
 Deep Sleep Mode Feature...........................................................................................8
 Communication Ports .........................................................................................................9
 Installation..........................................................................................................................10 
 Dimensions ...................................................................................................................10 
 Mounting on panel.........................................................................................................10 
 Terminal Description......................................................................................................12 
 Typical Wiring Diagram .................................................................................................14 
 Module Display ..................................................................................................................16 
 Monitoring Mode ...........................................................................................................16 
 Description of Control keys..............................................................................................19 
 Functions of Control keys..............................................................................................19 
 Configuration Mode...........................................................................................................20 
 List of Configurable Parameters....................................................................................21 
 Digital Input Sources Selection .....................................................................................30 
 Digital Output Source Selection ....................................................................................31 
 Module Operation ..............................................................................................................33 
 Auto Mode.....................................................................................................................33 
 Manual Mode ................................................................................................................37 
 Alarms ................................................................................................................................38 
 Troubleshooting.................................................................................................................41 
 Introduction to Communication Protocol........................................................................43 

 
GC1100 SEDEMAC 
 
Page | v 
 
 RS485 MODBUS Based Protocol......................................................................................43 
 Connection Details.....................................................................................................43 
 Precautions................................................................................................................44 
 Function Code Used ..................................................................................................44 
 Register Map .............................................................................................................46 
 Protocol for CAN-Based Communication........................................................................51 
 Connection Details.....................................................................................................51 
 Structure of Communication ......................................................................................51 
 Packet Structure ........................................................................................................58 
Notes .........................................................................................................................................59 
 

 
GC1100 SEDEMAC 
 
Page | vi 
 
List of Figures 
Figure 1: GC1100 genset controller's front fascia.........................................................................2
Figure 2: Connectors of 10.16 mm pitch ......................................................................................3
Figure 3: Connectors of 5.08 mm pitch ........................................................................................3
Figure 4: Connectors of 3.5 mm pitch ..........................................................................................3
Figure 5: SCP connection ............................................................................................................6
Figure 6: Dimensions of the GC1100 genset controller ..............................................................10 
Figure 7: Fixing clip and screw supplied along with controller....................................................11 
Figure 8: Controller mounting on the panel using the fixing clips ...............................................11 
Figure 9: GC1100 genset controller from backside ....................................................................12 
Figure 10: GC1100 genset controller power circuit (used in the Auto Mains Failure Mode) .......14 
Figure 11: GC1100 genset controller control circuit (used in the Auto Mains Failure mode) ......15 
Figure 12: Control keys function.................................................................................................19 
Figure 13: Configuration mode screen .......................................................................................20 
Figure 14: Configuration mode authentication page screen .......................................................20 
Figure 15: Saving setting screen................................................................................................20 
Figure 16: SMD for AMF mode...................................................................................................34 
Figure 17: SMD for auto exercise mode.....................................................................................35 
Figure 18: SMD for cyclic mode .................................................................................................36 
Figure 19: SMD for manual mode ..............................................................................................37 
Figure 20: RS485 MODBUS connection with the help of two core shielded twisted pair cable..43 
 

 
GC1100 SEDEMAC 
 
Page | vii 
 
List of Tables 
Table 1: Features list ....................................................................................................................1
Table 2: 10.16 mm pitch connector details ...................................................................................3
Table 3: 5.08 mm pitch connectors details ...................................................................................3
Table 4: 3.5 mm pitch connector details .......................................................................................4
Table 5: Power supply specifications............................................................................................4
Table 6: Generator voltage and frequency measurements...........................................................4
Table 7: Load current measurements ...........................................................................................5
Table 8: Mains voltage and frequency measurements .................................................................5
Table 9: Digital inputs ...................................................................................................................6
Table 10: Analog resistive sensor inputs ......................................................................................6
Table 11: Analog voltage/current input..........................................................................................7
Table 12: Magnetic pickup input ...................................................................................................7
Table 13: Digital outputs ...............................................................................................................7
Table 14: D+ CHG ALT.................................................................................................................8
Table 15: Sensor common point...................................................................................................8
Table 16: Communication ports....................................................................................................9
Table 17: Details of GC1100 terminals .......................................................................................12 
Table 18: Screens of engine status and operating mode............................................................16 
Table 19: Control keys in different modes ..................................................................................19 
Table 20: Configurable parameters ............................................................................................21 
Table 21: Digital input sources selection ....................................................................................30 
Table 22: Engine temperature sensor calibration .......................................................................31 
Table 23: Fuel level sensor calibration .......................................................................................31 
Table 24: LOP sensor calibration................................................................................................31 
Table 25: LOP sensor (4-20mA) calibration................................................................................31 
Table 26: Digital output source selection ....................................................................................31 
Table 27: Alarm actions ..............................................................................................................38 
Table 28: Alarms and their causes .............................................................................................38 
Table 29: Common faults and their remedial actions..................................................................41 
Table 30: RS485 MODBUS communication configuration setting ..............................................43 
Table 31: Details of function codes.............................................................................................44 
Table 32: Command from MODBUS master for Function 4........................................................44 

 
GC1100 SEDEMAC 
 
Page | viii 
 
Table 33: Normal response from genset controller slave for Function 4.....................................44 
Table 34: Command from MODBUS master for Function 16......................................................45 
Table 35: Normal response from genset controller slave for Function 16...................................45 
Table 36: Command from MODBUS master for Function 3........................................................45 
Table 37: Normal response from genset controller slave for Function 3.....................................46 
Table 38: Register map for input registers..................................................................................46 
Table 39: Register map for holding registers ..............................................................................50 
Table 40: Interpretation of alarm status results...........................................................................50 
Table 41: Structure of communication ........................................................................................51 
Table 42: Structure of broadcasted message .............................................................................57 
Table 43: Structure of command message .................................................................................57 
Table 44: Structure of command message received over CAN ..................................................58 